Method for taking at least one sample of metal powder and capsule for a sample of metal powder

Abstract

The invention relates to a method for taking a sample of metal powder (12A) during the manufacture of a part (50) by additive manufacturing from a metal powder (12), for example by laser melting on a bed of metal powder, the method comprising at least one manufacturing step, during which at least one capsule (30) containing metal powder (12A) is manufactured simultaneously with the manufacture of the part (50). Figure for the abstract: Fig. 1.

Description

Title of the invention: Method for taking at least one sample of metal powder and capsule for a sample of metal powder Technical field

[0001] The present disclosure relates to a method for taking at least one sample of metal powder during the manufacture of a part by additive manufacturing from a metal powder. The present disclosure also relates to a capsule for a sample of metal powder obtained by such a taking method. Prior art

[0002] Taking a sample of material during the manufacture of a part makes it possible to trace the different elements used for the manufacture of the part and to be able to carry out subsequent analyses, for example to try to identify the origin of mechanical or physico / chemical behavior, aging or even the origin of a possible defect in the part, and this throughout the life of the part.

[0003] In the context of parts manufactured by additive manufacturing from metal powder, metal powder is usually taken at the end of manufacturing, from the upper layers of powder or during the recovery of the unsolidified powder.

[0004] Indeed, in additive manufacturing processes using metal powder, it is only possible to take powder samples at the end of the manufacturing of the part, so as not to disturb the manufacturing of the part itself, for example so as not to disturb the controlled atmosphere in which the part is manufactured.

[0005] However, such known sample collections are not faithfully representative of the material actually used in the part or in a specific area of ​​the part, so that analyses possible from such samples can only provide relatively approximate results.

[0006] There is therefore a need for sample collections that allow more detailed and representative analyses to be carried out. Statement of the invention

[0007] One embodiment relates to a method for taking at least one sample of metal powder during the manufacture of a part by additive manufacturing from a metal powder, for example by laser fusion on a bed of metal powder.

[0008] More particularly, the sampling method comprises at least one manufacturing step during which at least one capsule containing metal powder is manufactured simultaneously with the manufacture of the part.

[0009] An additive manufacturing process by laser fusion on a powder bed is also known to those skilled in the art by the acronym “LBM” for “Laser Beam Melting” in English.

[0010] For example, a metal powder is a powder comprising at least 50% by mass of metal in powder form.

[0011] It is then possible to manufacture a single capsule, or a plurality of capsules in order to be able to multiply the sampling zones of the metal powder. Subsequently, and unless otherwise indicated, by "the capsule" is meant "the at least one capsule".

[0012] The capsule manufactured simultaneously with the part is filled, as the part is manufactured, in an internal volume of the capsule, with the successive layers of metal powder used for the manufacture of the part and the capsule.

[0013] Furthermore, slag and other projections may also be found in the capsule, within the sample of metal powder.

[0014] In other words, the capsule forms a receptacle, manufactured and filled with metal powder, slag and projections, simultaneously with the manufacture of the part. At the end of the manufacture of the part, the capsule therefore contains a sample of metal powder and any slag and other projections, arranged layer by layer, corresponding to the layers of metal powder which were successively and selectively melted for the manufacture of the part.

[0015] Such a sample of metal powder is representative of the layers of metal powder used to manufacture the part. Furthermore, a subsequent analysis of any slag and projections can provide additional information on the quality of the material obtained after melting to obtain the part.

[0016] In some embodiments, the capsule may extend over all or part of the height of the part, the height being the stacking direction of the successive layers of powder. In other embodiments, the capsule may extend beyond the height of the part, the height being the stacking direction of the successive layers of powder.

[0017] It is thus possible to obtain a sample of metal powder representative, according to the height direction, of only a portion or of the entire part, thanks to which it is possible to refine the fineness of the sampling according to the needs.

[0018] In some embodiments, the sampling method may include at least one sealing step, during which the capsule is sealed simultaneously with or after the manufacture of the part.

[0019] By sealing the capsule, i.e. an internal volume of the capsule receiving the metal powder, any slag and projections, the metal powder sample is hermetically sealed. This can make it possible to secure the sampling of metal powder. metal, and in particular to ensure that the metal powder sample will not be inadvertently spilled.

[0020] This can also make it possible to store the metal powder sample in a controlled atmosphere, at least isolated from the outside. It is thus possible to better preserve the physicochemical characteristics of the metal powder thus collected for subsequent analyses. In particular, this can be particularly advantageous when the metal powder comprises metal capable of oxidizing, such as aluminum, titanium, certain steels, etc.

[0021] By sealing the capsule, the internal volume of the capsule and the volume of metal powder collected are controlled. By knowing such an internal volume, or predetermined volume, it is then possible by simply measuring the mass of the capsule, without opening it, to deduce the density of the metal powder, making it possible to obtain initial elements of analysis.

[0022] In certain embodiments, the sampling method may comprise at least one removal step, during which the capsule is removed from a manufacturing tray, in particular by cutting, in particular by wire electro-erosion. Wire electro-erosion cutting is also known to those skilled in the art by the acronym “EMD” for “Electrical Discharge Machining” in English.

[0023] The capsule may be secured to a manufacturing tray. The manufacturing tray may be an element of an additive manufacturing device within which the sampling method is implemented. The part and / or the capsule may be manufactured secured to the manufacturing tray. When manufacturing is complete, it is possible to remove the capsule from the tray, for example by cutting a base of the capsule secured to the tray by EMD.

[0024] In certain embodiments, the removal step, during which the capsule is removed from the manufacturing plate, is prior to a step of heat treatment of the part.

[0025] The final part may, for example, be subjected to heat treatment after its manufacture. Such heat treatment may take place when the part is still attached to the manufacturing plate, while the capsule has previously been deposited.

[0026] Removing the capsule before such possible heat treatment can help preserve the metal powder and avoid possible deterioration.

[0027] In certain embodiments, a laser powder bed fusion additive manufacturing device may be used comprising at least one laser, in particular a plurality of lasers. The capsule containing the metal powder sample is then manufactured by the laser. In particular, each laser may be used to manufacture a capsule distinct from the capsules manufactured by the other lasers.

[0028] This can allow for further refined analysis, with each capsule enclosing a sample of metal powder, slag and projections specific to each laser used for the manufacture of the part.

[0029] One embodiment relates to a capsule for a sample of metal powder obtained by the sampling method according to any of the embodiments described herein.

[0030] It is understood that the capsule is filled with metal powder, slag and projections. For example, the capsule may be sealed. For example, the capsule is factory sealed, and forms a single-piece entity housing a sample of metal powder, slag and projections. Such a capsule may be stored and archived for a long period, before using its contents for analysis.

[0031] In some embodiments, the capsule may comprise a base and a body defining an internal volume housing the metal powder sample. For example, the base may be more rigid than the body.

[0032] For example, the base may be more rigid than the body, in compression, tension, torsion and / or bending. Such a ratio of rigidities may allow the base to support a step of cutting or tearing off a manufacturing tray of an additive manufacturing device without altering the capsule, while allowing sufficient internal volume to be provided to accommodate a quantity of metal powder necessary for subsequent analyses.

[0033] In certain embodiments, the capsule may comprise a sealing cap for the internal volume housing the sample of metal powder, in particular the sealing cap being able to be broken.

[0034] The sealing cap can be manufactured during a capsule sealing step.

[0035] Such a sealing plug may be configured to, when separated from the rest of the capsule, provide access to the internal volume and to the metal powder housed within the internal volume constituting the metal powder sample.

[0036] Such a configuration may, for example, make it possible to avoid soiling the sample of metal powder housed within the capsule when opening the capsule, such soiling being likely to occur if the capsule had to be machined, for example cut, in order to be opened.

[0037] In some embodiments, the sealing plug may be connected to a body, for example the body delimiting the internal volume housing the sample of metal powder, via a sacrificial portion.

[0038] Such a sacrificial portion may, for example, form an intermediate portion, such as a neck, connecting the sealing plug to the body, this intermediate portion having a wall thinned relative to the sealing plug and relative to the body, the thinned wall being able to be configured to break under the application of a predetermined mechanical stress on the sealing plug.

[0039] In some embodiments, the sealing plug may have a portion configured to be manipulated with a hand tool, the portion comprising, for example, at least one flat and / or at least one through hole.

[0040] For example, the sealing plug may have a general blade shape configured to be able to be taken between the jaws of pliers, a screw head to be able to be manipulated with a wrench and / or a screwdriver.

[0041] For example, the sealing plug may have a through hole configured to receive the hand tool, for example a screwdriver shank.

[0042] Such a configuration allows easy handling and removal of the sealing cap relative to the rest of the capsule. Brief description of the drawings

[0043] The object of the present disclosure and its advantages will be better understood upon reading the detailed description given below of different embodiments given as non-limiting examples. The present description is given with reference to the appended figures, in which:

[0044] [Fig-1] [Fig.l] represents a perspective view of a step of a pre-processing process lifting of metal powder sample according to the invention;

[0045] [Fig.2] [Fig.2] represents a partial sectional view along plane II of [Fig.l]; and

[0046] [Fig.3] [Fig.3] represents a capsule obtained by the sample collection method illustrated in Figures 1 and 2. Description of the embodiments

[0047] Figures 1 and 2 respectively represent a perspective view and a partial sectional view of a step of a method for taking a sample of metal powder according to the invention, in particular during the manufacture of a part by additive manufacturing from a metal powder.

[0048] More particularly, figures 1 and 2 represent an additive manufacturing device 10 from metal powder 12. In the example presented, the additive manufacturing device 10 is an additive manufacturing device by laser fusion on a bed of metal powder.

[0049] In particular, the additive manufacturing device 10 comprises - a manufacturing tray 14, - at least one laser 16, in particular a plurality of lasers 16, for example three lasers 16, and - at least one blade 18 for depositing metal powder 12.

[0050] The deposition blade 18 may comprise a powder reservoir 18A. In addition, the blade 18 may have a powder deposition nozzle 18B and at least one scraper 18C.

[0051] The squeegee 18C is configured to uniformize a layer of deposited metal powder 12.

[0052] Such an additive manufacturing device 10 is otherwise known to those skilled in the art and is not described in more detail.

[0053] The additive manufacturing device 10 may also comprise any other powder depositing device.

[0054] In [Fig.l], a volume of deposited metal powder 12 is symbolically represented by broken lines 11.

[0055] To manufacture a part 50 using the additive manufacturing device 10, for example during manufacturing as shown in FIGS. 1 and 2, a first layer of metal powder 12 is deposited directly on the manufacturing plate 14 using the deposition blade 18, to then be melted selectively using the laser 16, in particular the plurality of lasers 16.

[0056] Next, a new layer of metal powder 12 is deposited using the deposition blade 18, to then be selectively melted using the laser 16, in particular the plurality of lasers 16, and so on.

[0057] Figures 1 and 2 represent an intermediate step in the manufacture of the part 50. Of course, the part 50 shown is purely illustrative and can have all kinds of shapes and sizes.

[0058] In addition, any metal powder suitable for such type of additive manufacturing can be used.

[0059] A method for taking a sample of metal powder and an associated capsule 30 according to the present disclosure will now be described in more detail with reference to FIGS. 1 to 3.

[0060] In Figures 2 and 3, only one capsule 30 is shown, but of course the following description applies to all the capsules 30 shown in [Fig.l].

[0061] Figures 1 and 2 represent a method of taking at least one sample of metal powder 12A during manufacturing of the part 50 by additive manufacturing from the metal powder 12, for example by laser fusion on a bed of metal powder.

[0062] More specifically, the method comprises at least one step of manufacturing at least one capsule 30 containing metal powder 12 simultaneously with the manufacturing of the part 50.

[0063] In the example of [Fig.2], the capsule 30 in manufacture defines an interior volume V containing slag and projections 13, resulting from the manufacture of the part 50.

[0064] In the example presented, a capsule 30 is manufactured containing powder me metal 12 by laser, namely three capsules 30 respectively manufactured with a laser 16.

[0065] [Fig. 3] represents the capsule 30 obtained by the sample collection method illustrated in FIGS. 1 and 2, in particular before removal of the manufacturing plate 14.

[0066] More specifically, [Fig. 3] represents the capsule 30 when it is finished, the part 50 also being finished.

[0067] In [Fig. 3], all the metal powder 12 that has not been melted to make the part 50, the capsule 30 or that is not enclosed in the capsule 30 has been removed. This leaves only the part 50 and the capsule 30 filled with a sample of metal powder 12A.

[0068] According to the example presented in [Fig. 3], the part 50 and the capsule 30 are still integral with the plate 14. In other words, [Fig. 3] represents the capsule 30 containing the sample of metal powder 12A obtained by the sampling method according to the invention.

[0069] In addition, the sampling method may comprise a step of removing the capsule 30 from the plate 14, for example by wire electroerosion cutting. For this purpose, a cutting device 40, in particular by wire electroerosion, may be used during the removal of the capsule 30.

[0070] According to an alternative embodiment, during the removal step, the part 50 can also be removed from the plate 14, simultaneously with the capsule 30, or sequentially, i.e. before or after the capsule 30.

[0071] According to another alternative embodiment, during the removal step, the capsule 30 is only removed from the manufacturing plate 14, while the part 50 is left integral with the manufacturing plate 14, for example to subsequently undergo a heat treatment step once the capsule 30 has been removed from the manufacturing plate 14.

[0072] In other words, in such another embodiment, the capsule 30 is removed from the manufacturing plate 14 before a heat treatment step of the part 50 is carried out.

[0073] In the example of [Fig.3], the capsule 30 extends over the entire height H of the part 50, the height H extending in a stacking direction of the successive layers of metal powder 12.

[0074] When manufacturing the capsule 30, during the sample collection method of the present example, a sealing plug 30A is manufactured during a step of sealing the capsule 30.

[0075] According to an alternative embodiment, during the sealing step, the sealing plug 30A is manufactured after the manufacture of the part 50 is completed.

[0076] In other words, in such an alternative embodiment, the capsule 30 comprises in a sealing plug 30A the internal volume V housing the sample of metal powder 12A.

[0077] Alternatively, according to another embodiment variant, during the sealing step, the sealing plug 30A is manufactured simultaneously with the manufacturing of the part 50 being completed. In particular, the sealing plug 30A may be breakable. For this purpose, the sealing plug 30A may be connected to a body 30B of the capsule 30, delimiting the internal volume V housing the sample of metal powder 12A, by means of a sacrificial portion 30C. In particular, the sacrificial portion 30C may form an intermediate portion, such as a neck, having a wall PI thinned relative to a wall PB of the sealing plug 30A and relative to a wall PC of the body 30B.

[0078] Thus, the thinned wall PI of the sacrificial portion 30C can be configured to rupture under the application of a predetermined mechanical stress on the sealing plug 30A.

[0079] The sealing plug 30A may also have a portion 30A1 configured to be manipulated with a hand tool (not shown), such as pliers, a wrench, a screwdriver, a rod, etc.

[0080] In the example of [Fig. 3], the portion 30A1 comprises two flats 30A11 arranged on two opposite faces of the sealing plug 30A. In particular, the flats 30A11 are, for example, parallel to the plane of [Fig. 3].

[0081] Furthermore, the portion 30A1 also comprises a through hole 30A12, into which the hand tool can be inserted and leveraged to detach the sealing plug 30A from the body 30B.

[0082] In addition, the capsule 30 may comprise a base 30D. The base 30D and the body 30B delimit the internal volume V housing the sample of metal powder 12A.

[0083] In particular, the base 30D is more rigid than the body 30B.

[0084] According to one embodiment, the body 30B has a cylinder shape with an axis extending in the direction of the height H, and may have a circular section. However, any other shape is possible.

[0085] The base 30D may have substantially a solid disc shape, allowing the rigidity of the base 30D to be greater than the rigidity of the body 30B.

[0086] The internal volume V of the capsule 30 is predetermined.

[0087] Although the present invention has been described with reference to specific embodiments, it is obvious that modifications and changes may be made to these examples without departing from the general scope of the invention as defined by the claims. In particular, individual features of the various illustrated / mentioned embodiments may be combined in additional embodiments. Therefore, the description and drawings should be considered in an illustrative rather than restrictive sense.

[0088] It is also obvious that all the characteristics described with reference to a sampling method are transposable, alone or in combination, to the additive manufacturing device 10, and conversely, all the characteristics described with reference to an additive manufacturing device 10 are transposable, alone or in combination, to a sampling method.

Claims

Claims

1. Method for taking at least one sample of metal powder (12A) during the manufacture of a part (50) by additive manufacturing from a metal powder (12), for example by laser fusion on a metal powder bed, the method comprising at least one manufacturing step, during which at least one capsule (30) containing metal powder (12) is manufactured simultaneously with the manufacture of the part (50).

2. A sampling method according to claim 1, comprising at least one sealing step, during which the capsule (30) is sealed simultaneously with or after the manufacture of the part (50).

3. A sampling method according to claim 1 or 2, comprising at least one removal step, during which the capsule (30) is removed from a manufacturing plate (14), in particular by cutting, in particular by wire electroerosion.

4. A sampling method according to claim 3, wherein the depositing step is prior to a step of heat treatment of the part (50).

5. Sampling method according to any one of the preceding claims, in which an additive manufacturing device by laser fusion on a powder bed (10) comprising at least one laser (16) is used, and in which the capsule (30) containing the sample of metal powder (12A) is manufactured by the laser (16).

6. Capsule (30) for a sample of metal powder (12A) obtained by the sampling method according to any one of the preceding claims.

7. Capsule (30) according to claim 6, comprising a base (30D) and a body (30B) delimiting an internal volume (V) housing the sample of metal powder (12A).

8. Capsule (30) according to claim 6 or 7, comprising a sealing plug (30A) of an internal volume (V) housing the sample of metal powder (12A), in particular the plug (30A) being breakable.

9. Capsule (30) according to claim 8, wherein the sealing plug (30A) is connected to a body (30B) via a sacrificial portion (30C).

10. Capsule (30) according to claim 8 or 9, wherein the sealing cap (30A) has a portion (30A1) configured to be manipulated with a manual tool, in particular the portion (30A1) comprising at least one flat (30A11) and / or at least one through hole (30A12).

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